Monocoque and semi-monocoque passenger seats with ergonomic design

ABSTRACT

Described are ergonomic passenger seats that may include monocoque or semi-monocoque seat backs, cellular suspension cushions, and tray tables with support arms that may be located within the interior volume of the monocoque or semi-monocoque seat backs when in their stowed positions. The passenger seats offer enhanced passenger comfort and space while providing a lightweight, simple to manufacture design. Monocoque and semi-monocoque seat backs may form integral parts of passenger seats to support additional loads without need for heavy, complex structures. The space within the monocoque or semi-monocoque seat back may then be used for storage or suspension cushions that offer improved comfort with a lighter seat frame. Monocoque and semi-monocoque seat backs may also facilitate the adoption of several other seating mechanisms, such as new seat mounts that allow for improved seat motion that allows for passenger recline with reduced impingement on other passengers&#39; space.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional patent application of U.S. applicationSer. No. 15/317,527, filed on Dec. 9, 2016, (“the ‘527 application”),which is the U.S. national stage entry of International ApplicationSerial No. PCT/US2015/035102 (“the '102 application”), filed on Jun. 10,2015, entitled “Monocoque and Semi-Monocoque Passenger Seats withErgonomic Design”, which is related to and claims priority benefits fromU.S. Provisional Application Ser. No. 62/010,213 (“the '213application”), filed on Jun. 10, 2014, entitled “Composite ClamshellAircraft Seatback”, U.S. Provisional Application Ser. No. 62/034,886(“the '886 application”), filed on Aug. 8, 2014, entitled “SignatureSeat”, and U.S. Provisional Application Ser. No. 62/140,493 (“the '493application”), filed on Mar. 31, 2015, entitled “Tray Table for AircraftPassenger Seat with Concealed Arms”. The '527, '102, '213, '886, and'493 applications are hereby incorporated in their entireties by thisreference.

FIELD OF THE INVENTION

The field of the invention relates to passenger seats or the like, andmore particularly to monocoque construction and ergonomically designedpassenger seats.

BACKGROUND

There has been continuous movement in carrier industries, particularlywith air carriers, to move towards passenger seats, which are lighter,simpler, and easier to manufacture and assemble. Lighter, more compactseats offer improved fuel economy, increase available payload forpassengers and luggage, and allow for extra passenger space in existingseating arrangements or opportunities for more compact seatingarrangements while maintaining passenger space at current levels. Thepassenger seat is also a major design feature and the structure thatpassengers are most often in contact with during travel. As such, thereis a simultaneous push for more visually appealing designs and improvedergonomics and passenger comfort.

Traditional passenger seats are manufactured with internal frames thatare covered with cushions and outer panels that provide the seatingsurface. These seats can be heavy, bulky, and complex to manufacture,thus resulting in standardized designs. As a result, extra featurestypically are added onto the seat structures instead of being integratedfor a more seamless, efficient design. Existing seat structures arenormally built up from metal tubes, bars, or stampings, which makes itdifficult if not impossible to include complex curvatures that provideenhanced support for varying passenger physiologies.

In some cases, it may be desirable to design a seat based on ergonomicconcepts and configured to provide adequate support for passengers thatfall within the range of the fifth to ninety-fifth statisticalpercentile for body size or shape. Compound or anatomically designedcurvatures to the seat back and head rest may be designed to not onlycradle the passenger during lateral loads, but also to provide supportand maintain alignment of the head, neck, and spine. The seat pan orbottom may be designed to provide proper hip alignment and maintainpressure on the tuberosity of the ischium without creating pressurepoints. In certain cases, the seat structure may incorporate suspensioncushions with anisotropic properties so that cushioning and support maybe varied in different directions to provide optimal support and comfortto the passenger.

In certain cases, the use of a monocoque or semi-monocoque seat back mayfacilitate the design of a passenger seat that is lighter, simpler tomanufacture, more compact, while still providing excellent passengercomfort and support. In monocoque designs, the outer skin is the primaryload-bearing structure. Similarly, a semi-monocoque design uses theouter skin as the primary load-bearing structure, but incorporatesadditional inner bracing to strengthen the component. Monocoque orsemi-monocoque seat structures, particularly seat backs, may provideadditional design freedom as compared with traditional seat frameconstructions. Monocoque or semi-monocoque seat structures allow formore freedom in aesthetic design, more complex curvatures for ergonomicsupport, and more internal space that may be used for locating traytables, storage pockets, and internal passenger suspension cushions,which would otherwise be too bulky or impossible to fit to existing seatstructures.

SUMMARY

The terms “invention,” “the invention,” “this invention” and “thepresent invention” used in this patent are intended to refer broadly toall of the subject matter of this patent and the patent claims below.Statements containing these terms should be understood not to limit thesubject matter described herein or to limit the meaning or scope of thepatent claims below. Embodiments of the invention covered by this patentare defined by the claims below, not this summary. This summary is ahigh-level overview of various aspects of the invention and introducessome of the concepts that are further described in the DetailedDescription section below. This summary is not intended to identify keyor essential features of the claimed subject matter, nor is it intendedto be used in isolation to determine the scope of the claimed subjectmatter. The subject matter should be understood by reference toappropriate portions of the entire specification of this patent, any orall drawings and each claim.

According to certain embodiments of the present invention, a monocoqueseat back may comprise a forward panel, wherein the forward panel maycomprise a forward concave face and a forward convex face, an aft panel,wherein the aft panel may comprise an aft concave face and an aft convexface. The forward panel may also comprise a forward panel matingperimeter and the aft panel may comprise an aft panel mating perimeterwherein the forward panel mating perimeter may comprise complimentarygeometry to the aft panel mating perimeter and wherein the forward panelmating perimeter may be affixed to the aft panel mating perimeter suchthat the forward concave face and the aft concave face substantiallyenclose a volume.

In some embodiments, the forward panel mating perimeter and the aftpanel mating perimeter may form a butt joint. The monocoque seat backmay further comprise a backing member, wherein the backing member mayreinforce the butt joint of the forward panel mating perimeter and theaft panel mating perimeter.

In some embodiments, the forward panel mating perimeter and the aftpanel mating perimeter may form a lap joint. In further embodiments, theforward panel mating perimeter and the aft panel mating perimeter mayform a splice joint.

In some embodiments, the forward panel mating perimeter and the aftpanel mating perimeter form a scarf joint.

In certain embodiments, the monocoque seat back may comprise an internalbaffle. The monocoque seat back may comprise an integrated stowagepocket.

In some embodiments, the monocoque seat back may further comprise atleast one integrated armrest mounting point.

In some embodiments, the forward panel may comprise a composite. Thecomposite may comprise carbon fiber.

In certain embodiments, the aft panel may comprise a composite. Thecomposite may comprise carbon fiber.

In some embodiments, the monocoque seat back may further comprise a foamfill within the volume.

According to certain embodiments of the present invention, a monocoqueseat back may comprise a structural skin with an exterior surface and aninterior surface, the interior surface of the structural skin may definea substantially enclosed volume, the exterior surface of the structuralskin may be configured to provide the surface geometry of the monocoqueseat back, and the structural skin may substantially support any loadsimposed on the monocoque seat back.

In certain embodiments, the structural skin may comprise a composite.The composite may comprise carbon fiber.

In some embodiments, the monocoque seat back may further comprise aninternal baffle. The monocoque seat back may further comprise anintegrated stowage pocket.

In certain embodiments, the monocoque seat back may further comprise afoam fill within the substantially enclosed volume.

In some embodiments, the monocoque seat back may further comprise atleast one integrated armrest mounting point.

According to certain embodiments of the present invention, a passengerseat tray table may comprise a tray, a first moveable support arm, and asecond moveable support arm wherein the first moveable support arm andthe second moveable support arm are pivotally coupled to the seat backpivot pin. The passenger seat tray table may also comprise a seat backpivot pin, wherein the first moveable support arm and the secondmoveable support arm are pivotally coupled to the seat back pivot pin,at least one stop mechanism fixedly coupled to the seat back pivot pin,wherein the at least one stop mechanism interferes with at least one ofthe first moveable support arm and the second moveable support arm whenthe tray table is in a deployed position, and wherein the first moveablesupport arm and the second moveable support arm are configured to belocated within a passenger seat back when the tray table is in a stowedposition.

In some embodiments, the at least one stop mechanism may be integratedwith the seat back pivot pin.

In certain embodiments, the at least one stop mechanism may comprise aprotrusion. In further embodiments, the at least one stop mechanism maycomprise a cam.

In certain embodiments, the at least one stop mechanism may comprise astop pin.

In some embodiments, the first moveable support arm and the secondmoveable support arm may be located within a monocoque seat back. The atleast one stop mechanism may be indexed to the seat back pivot pin.

In certain embodiments, at least one of the first moveable support armand the second moveable support arm may be pivotally coupled to the seatback pivot pin through a Z-link.

In certain embodiments, the at least one stop mechanism may interferewith the Z-link in the deployed position.

In some embodiments, the stowed position of the tray table may bedefined by the passenger seat back. The tray table may be configured tomove with the passenger seat back when in the stowed position.

According to certain embodiments of the present invention, an ergonomicpassenger seat may comprise a seat back that may comprise a compoundseat back curve configured to support a passenger falling within thefifth to ninety-fifth statistical percentile for body size or shape, aseat pan, a flexible bullnose affixed to a forward portion of the seatpan, a headrest that may comprise a compound headrest curve configuredto support a passenger head and neck falling within the fifth toninety-fifth statistical percentile for body size or shape, a firstsuspension cushion that may be integrated into the sat back, and atleast one low-rise spreader.

In certain embodiments, the flexible bullnose may comprise a polymer.

In some embodiments, the at least one low-rise spreader may comprise twomotion tracks. The two motion tracks of the at least one low-risespreader may be sloped in opposite vertical directions.

In certain embodiments, the compound headrest curvature may comprise anoccipital pocket.

In certain embodiments, the headrest may translate through a verticalmotion. The vertical motion of the headrest may comprise an arcingmotion.

In certain embodiments, the headrest may rotate about a horizontal axis.

In some embodiments, the seat back may be fixed with respect to the seatpan. In further embodiments, the seat back and the seat pan may comprisea single load-bearing structure.

In some embodiments, the passenger seat may comprise one or morearmrests affixed to the seat back.

In certain embodiments, the two motion tracks of the at least onelow-rise spreader may be configured such that the seat pan translatesdown and forward when the passenger seat transitions from an uprightposition to a reclined position.

In some embodiments, the first suspension cushion may comprise acellular material. The cellular material may comprise a variable cellsize.

In some embodiments, the cellular material may comprise a variable cellheight.

In certain embodiments, the cellular material may comprise a variablecell wall thickness.

In some embodiments, the cellular material may comprise a honeycombcell. In further embodiments, the cellular material may comprise asquare cell.

In some embodiments, the cellular material may comprise a circular cell.

In certain embodiments, the first suspension cushion may comprisesilicone.

In some embodiments, the first suspension cushion may comprise acompound curve configured to support the passenger falling within thefifth to ninety-fifth statistical percentile for body size or shape.

In certain embodiments, the passenger seat may further comprise a lumbarsupport. The lumbar support may be self-adjusting.

In certain embodiments, the seat back may comprise a semi-monocoquestructure.

In some embodiments, the seat back may comprise a monocoque structure.The monocoque structure may comprise a forward panel, an aft panel, anda first suspension cushion retaining member.

In some embodiments, the first suspension cushion may be disposed withinthe monocoque structure.

In certain embodiments, the passenger seat may further comprise at leastone aperture in the forward panel of the monocoque structure, whereinthe at least one aperture is configured such that a person fallingwithin the fifth to ninety-fifth statistical percentile for body size orshape is at least partially supported by the first suspension cushion.

In some embodiments, the seat pan may comprise a monocoque structure.

In certain embodiments, the passenger seat may further comprise a secondsuspension cushion, wherein the second suspension cushion is disposedwithin the monocoque structure of the seat pan.

In some embodiments, the seat pan may comprise a substantially planarsupport plate, a flexible core material, and a top plate.

In certain embodiments, the seat pan may further comprise at least oneaperture in the top plate of the seat pan, wherein the at least oneaperture is configured such that a person falling within the fifth toninety-fifth statistical percentile for body size or shape is at leastpartially supported by the flexible core material.

In some embodiments, the flexible core material may comprise silicone.

In certain embodiments, the flexible core material may comprise acellular material.

In some embodiments, the cellular material may comprise a variable cellsize. In further embodiments, the cellular material may comprise avariable cell height.

In some embodiments, the cellular material may comprise a variable cellwall thickness. The cellular material may comprise a honeycomb cell.

In some embodiments, the cellular material may comprise a square cell.

In certain embodiments, the cellular material may comprise a circularcell.

According to certain embodiments of the present invention, a passengerseat pan may comprise a substantially planar support plate, a flexiblecore material that may comprise a honeycomb cellular structure, a topplate that may comprise at least one aperture configured such that aperson falling within the fifth to ninety-fifth statistical percentilefor body size or shape is at least partially supported by the flexiblecore material. The substantially planar support plate may comprise theseat pan bottom, the top plate may comprise the sat pan top, theflexible core material may be disposed between the substantially planarsupport plate and the top plate, and a flexible bullnose may be affixedto the forward portion of the seat pan.

According to certain embodiments of the present invention, a passengerseat back may comprise a monocoque structure that may comprise a forwardpanel, an aft panel, and a suspension cushion retaining member, and asuspension cushion that may comprise a honeycomb cellular structure. Theforward panel may comprise an aperture configured such that a personfalling within the fifth to ninety-fifth statistical percentile for bodysize or shape is at least partially supported by the suspension cushion,and wherein the monocoque structure and the suspension cushion maycomprise a compound curve configured to support a passenger fallingwithin the fifth to ninety-fifth statistical percentile for body size orshape.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a monocoque seat back.

FIG. 2 is a rear perspective view of the monocoque seat back of FIG. 1.

FIG. 3 is an assembly drawing of a semi-monocoque seat back.

FIG. 4 is a sectional view of a monocoque seat back mating seam.

FIG. 5 is a sectional view of a monocoque seat back mating seam.

FIG. 6 is a perspective view of a passenger seat back with a tray tablein a deployed position.

FIG. 7 is a perspective view of a passenger seat back with a tray tablein a stowed position.

FIG. 8 is an assembly drawing of a tray table stop mechanism.

FIG. 9 is a perspective view of a tray table stop mechanism.

FIG. 10 is a perspective view of a tray table stop mechanism in a stowedposition.

FIG. 11 is a perspective view of a tray table stop mechanism in adeployed position.

FIG. 12 is a side elevation view of a tray table in a stowed position.

FIG. 13 is a side elevation view of a tray table in a deployed position.

FIG. 14 is a perspective view of a tray table in a deployed position.

FIG. 15 is a perspective view of a tray table in a stowed position.

FIG. 16 is a plan view of a cellular cushion.

FIG. 17 is a perspective view of a cellular cushion.

FIG. 18A is a front elevation view of a cellular suspension cushion.

FIG. 18B is an enlarged view of the cellular structure of the cellularsuspension cushion of FIG. 18A.

FIG. 19 is a front elevation view of a cellular suspension cushion.

FIG. 20 is a side elevation view of a cellular suspension cushion.

FIG. 21 is a sectional view of an ergonomic headrest.

FIG. 22 is a perspective view of an ergonomic headrest.

FIGS. 23A-23C are side elevation views of an ergonomic headrest indifferent translational positions.

FIG. 24 is a side elevation view of an ergonomic headrest passingthrough a curved range of motion.

FIG. 25 is a side elevation view of a low-rise spreader.

FIG. 26 is a side elevation view of a low-rise spreader withaccompanying passenger seat.

FIGS. 27A-27C are side elevation views of a reclining passenger seatpassing through the upright and reclined positions.

FIG. 28 is a sectional view of a seat pan with a bullnose.

FIG. 29 is an assembly drawing of a seat pan with bullnose.

FIG. 30 is a perspective view of an ergonomic seat back.

FIG. 31 is a front elevation view of an ergonomic seat back.

FIG. 32 is an assembly drawing of an ergonomic seat back.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is describedhere with specificity to meet statutory requirements, but thisdescription is not necessarily intended to limit the scope of theclaims. The claimed subject matter may be embodied in other ways, mayinclude different elements or steps, and may be used in conjunction withother existing or future technologies. This description should not beinterpreted as implying any particular order or arrangement among orbetween various steps or elements except when the order of individualsteps or arrangement of elements is explicitly described.

The described embodiments of the invention provide a monocoque andsemi-monocoque seat back, a tray table with tray table arms locatedwithin a seat back, and an ergonomic seat. While these structures aredescribed with reference to an airline passenger seat, they are by nomeans so limited. Rather, embodiments of the monocoque andsemi-monocoque seat back, the tray table with tray table arms locatedwithin a seat back, and the ergonomic seat may be used in any passengerseat including, but not limited to, automotive, marine, bus, train, orother commercial passenger seats.

Monocoque and Semi-Monocoque Seat Back

In some embodiments of the present invention, as shown in FIGS. 1 and 2,a monocoque seat back 100 comprises a forward panel 104 affixed to a aftpanel 112. The monocoque seat back 100 may be constructed without anyinternal framing, as the forward panel 104 and aft panel 112 are themain load bearing structures of the monocoque seat back 100. As shown,the forward panel 104 and aft panel 112 may be molded, formed, orotherwise made with complex shapes, curvatures, and structures toprovide additional support, attachment points, storage areas, or otherfeatures. In certain embodiments, the monocoque seat back 100 mayinclude an integrated stowage pocket 122 and/or an integrated monitorsurround 124 formed by the particular shaping and mating of the forwardpanel 104 and the aft panel 112. Quadrant arms 120 may be integratedwith, or affixed to, the monocoque seat back 100 and form part of theattachment of the monocoque seat back 100 to the passenger seat frameand other components (not shown).

FIG. 3 is an exploded view of a semi-monocoque seat back 102 withintegrated monitor surround 124 and integrated stowage pocket 122. Themonocoque seat back 100 (FIGS. 1 and 2) is similar in design,construction, materials, and assembly to the semi-monocoque seat back102, with the exception of the internal baffle 128. The semi-monocoqueseat back 102 may be comprised of a forward panel 104 and a aft panel112 with an internal baffle 128 sandwiched between the forward panel 104and aft panel 112. Quadrant arms 120 may be affixed to either theforward panel 104, aft panel 112, or sandwiched between the forward andaft panels 104, 112. In certain embodiments, the quadrant arms 120 maybe formed as an integral part of the forward panel 104, aft panel 112,or internal baffle 128. The internal baffle 128 provides extra stiffnessto the semi-monocoque seat back 102, and may be used to providestructure within the enclosed volume of the semi-monocoque seat back 102and provide additional functionality. In certain embodiments, theinternal baffle 128 may form part of the integrated monitor surround 124and integrated stowage pocket 122.

Still referring to FIG. 3, the forward panel 104 may be shaped to form aconcave face 106 and a convex face 108. Along the boundary of theconcave face 106 and convex face 108 is a mating perimeter 110.Similarly, the aft panel 112 may also be shaped with a concave face 114and a convex face 116, which meet at a mating perimeter 118. The matingperimeter 110 of the forward panel 104 may be shaped to be complimentaryto the mating perimeter 118 of the aft panel 112. The forward panel 104may then be joined to the aft panel 112 along a seam between the forwardpanel mating perimeter 110 and the aft panel mating perimeter 118.Because the forward panel 104 and aft panel 112 are arranged such thatthe forward panel concave face 106 and aft panel concave face 114 arearranged towards the interior of the semi-monocoque seat back 102, thereis space for the internal baffle 128 to be enclosed within the volumecreated by the forward and aft panels 104, 112. In certain embodiments,the semi-monocoque seat back 102 or monocoque seat back 100 (FIGS. 1 and2) may be formed with integrated fixtures, mounting points, or featuresthat would otherwise have to be separately made or attached. As shown inFIG. 3, aft panel 112 is formed with two pivot axis holes 130 throughwhich passes a pivot axis 126. The pivot axis holes 130 may then serveas a bearing surface for a rod or pin that passes through the pivot axisholes 130. This rod or pin (not shown) may then provide a pivot forreclining the semi-monocoque seat back 102, the attachment of armrests(not shown), or other functionalities.

FIGS. 4 and 5 are a sectional views of a monocoque or semi-monocoqueseat back 100, 102 that has been assembled from a forward panel 104 anda aft panel 112. The forward panel 104 comprises a convex face 108 and aconcave face 106. Similarly, the aft panel 112 comprises a convex face116 and a concave face 114. The forward panel concave face 106 and aftpanel concave face 114 are disposed towards one another and form theinner portion of the monocoque or semi-monocoque seat back 100, 102. Theforward panel 104 and aft panel 112 then enclose an internal volume 134,which may be used for storage or internal wiring. In some embodiments,the internal volume 134 may be filled with a foam or foam-like materialto facilitate floating in an emergency, or to provide additionalstrength to the monocoque or semi-monocoque seat back 100, 102. Theforward panel 104 comprises a forward panel mating perimeter 110, whichis of complimentary geometry to an aft panel mating perimeter 118. Theforward panel mating perimeter 110 may then be joined with the aft panelmating perimeter 118 to form a joint 132 where the forward panel 104 andaft panel 112 are connected to form the monocoque or semi-monocoque seatback 100, 102. In some embodiments, the joint 132 may be reinforced by abacking member 136, which provides additional support to the joint 132and gives extra area for affixing the forward panel 104 to the aft panel112.

Still referring to FIGS. 4 and 5, any number of methods of attachmentbetween the forward panel 104 and aft panel 112 may be used to constructmonocoque or semi-monocoque seat back 100, 102. For example, the forwardpanel mating perimeter 110 and aft panel mating perimeter 118 may bejoined in a butt joint, a butt joint with a backing member, a scarfjoint, a splice joint, and/or any other type of joining arrangement asdesired or required for a particular material, manufacturing process, ordesign. Furthermore, a wide variety of attachment methods may be used tosecure the forward panel 104 to the aft panel 112. For example, thejoint 132 between the forward panel 104 and the aft panel 112 may beheld together or fixed with the use of bonding agents such as, but notlimited to, glue, epoxy, adhesives, or the like. The joint 132 may alsobe fixed using fasteners such as screws, rivets, bolts, or othermechanical connection devices. In certain embodiments, the forward panel104 and aft panel 112 may be formed with bosses to facilitate aparticular means of attachment between the forward and aft panels 104,112. In some embodiments, the forward and aft panels 104, 112 may beformed with integrated tabs or fittings to allow the panels to snaptogether with or without the use of fasteners, adhesives, or otherjoining methods.

Referring to FIGS. 1-3, a monocoque or semi-monocoque seat back 100, 102may also be formed from a single-piece structural skin. In certainembodiments, the forward panel 104 and aft panel 112 may be formed,molded, or laid up as a single piece, which encloses a volume andprovides the structural skin for the monocoque or semi-monocoque seatback 100, 102.

The monocoque or semi-monocoque seat back 100, 102 of FIGS. 1-5 providesa number of advantages and opportunities for unique passenger seatconstructions. For example, the monocoque or semi-monocoque seat back100, 102 provides for a lighter, more compact seat back, and alsoprovides an internal volume 134, which may be used for storage, internalwiring, or the concealment of other components related to or affixed tothe passenger seat. The monocoque or semi-monocoque seat back 100, 102may be molded with attachment points or integrated hardware tofacilitate the attachment of arm rests directly to the seat back 100,102, reduce parts count, or provide extra structural support for theoverall seat structure. For example, the monocoque or semi-monocoqueseat back 100, 102 may be used as a load bearing structure to supportthe loads of a seat pan (not shown). A monocoque or semi-monocoque seatback 100, 102 also allows for additional design flexibility foraesthetically pleasing seat designs, as compared to traditional internalframe seat backs. In certain embodiments, the monocoque orsemi-monocoque seat back 100, 102 may be preferably made from a varietyof materials including, but not limited to, composites, carbon fiber,plastic, metals, or other materials that may be stamped, laid up,molded, or otherwise formed into sheets. In certain embodiments,composites such as carbon fiber may be preferable due to theirflexibility in providing different material thicknesses at variouslocations of the monocoque or semi-monocoque seat back 100, 102.

Any of the above described components, parts, or embodiments may take ona range of shapes, sizes, or materials as necessary for a particularapplication of the described invention. The components, parts, ormechanisms of the described invention may be made of any materialsselected for the suitability in use, cost, or ease of manufacturing.Materials including, but not limited to aluminum, stainless steel, fiberreinforced plastics, carbon fiber, composites, polycarbonate,polypropylene, other metallic materials, or other polymers may be usedto form any of the above described components.

Different arrangements of the components depicted in the drawings ordescribed above, as well as components and steps not shown or describedare possible. Similarly, some features and sub-combinations are usefuland may be employed without reference to other features andsub-combinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentswill become apparent to readers of this patent. Accordingly, the presentinvention is not limited to the embodiments described above or depictedin the drawings, and various embodiments and modifications may be madewithout departing from the scope of the claims below.

Tray Table with Tray Table Arms Located Within a Seat Back

In some embodiments of the present invention, as shown in FIGS. 6 and 7,a tray table 202 may be integrated into a seat back 200 such that thetray table arms 204 are only slightly visible in the deployed position(FIG. 6). In the stowed position (FIG. 7), the tray table 202 may beflush with the seat back 200 and the tray table arms 204 and anyassociated hardware will be located within the seat back 200.

FIGS. 8-11 are perspective views of certain embodiments of theconnection between a tray table arm 204 and the seat back pivot pin 212.The tray table arm 204 may include a tray table arm pivot 205, which iscoupled to the seat back pivot pin 212 in such a way as to allowrotation of the tray table arm 204 about the seat back pivot pin 212.The seat back pivot pin 212, which may include a groove 216, passesthrough the tray table arm pivot 205 so that the groove 216 may engagethe tongue 218 of the stop mechanism 206. A bolt 220 and washer 222 maybe used to affix the stop mechanism 206 to the seat back pivot pin 212.A bushing 214 may be placed between the tray table arm pivot 205 and theseat back pivot pin 212 to facilitate rotation of the tray table arm 204about the seat back pivot pin 212.

Still referring to FIGS. 8-11, the seat back pivot pin 212 may notrotate due to its connection to the seat, seat back, and/or otherstructural components (not shown). The tray table arm 204, which isconnected to the seat back pivot pin 212 through the tray table armpivot 205 and optional bushing 214, is free to rotate about the seatback pivot pin 212. The stop mechanism 206, which may include anoptional protrusion 208 and/or pin 210, is indexed to the seat backpivot pin 212 by the engagement of the tongue 218 into the groove 216and may not rotate with respect to the seat back pivot pin 212. The freerotation of the tray table arm 204 and fixation of the stop mechanism206 provides for a relative rotational movement between the tray tablearm 204 and the stop mechanism 206.

Referring to FIGS. 10 and 11, the tray table arm 204 may move betweenstowed (FIG. 10) and deployed (FIG. 11) positions. As the tray table arm204 rotates between its stowed and deployed positions, stop mechanism206, stop mechanism protrusion 208, and/or stop mechanism pin 210 mayinterfere with the motion of the tray table arm 204. In the deployedposition (FIG. 11), the stop mechanism 206, stop mechanism protrusion208, and/or stop mechanism pin 210 may stop the motion of the tray tablearm 204 to define the limit of motion in the deployed position.

FIGS. 12 and 13 are transparent side views of a tray table 202 locatedwithin a seat back 200 in stowed and deployed positions, respectively.The tray table 202 is pivotally coupled to the tray table arms 204. Thetray table arms 204 may then be pivotally coupled to the seat back pivotpin 212 as described in FIGS. 8-11 above. The stop mechanism 206, whichis indexed to the seat back pivot pin 212 by groove 216, may includeprotrusion 208 and pin 210. The relative angle of groove 216 on seatback pivot pin 212 locates the stop mechanism 206 and the protrusion 208and pin 210. In the stowed position (FIG. 12), the tray table arm 204does not contact the stop mechanism 206, protrusion 208, or pin 210. Thetray table arm 204 may freely rotate about the seat back pivot pin 212in the stowed position. While the tray table 202 is stowed, the seatback 200 defines the closed position of the tray table 202. Furthermore,the seat back 200 rotates about the seat back pivot pin 212 duringrecline, so the tray table 202, tray table arms 204, and seat back 200will move as a single unit when the tray table 202 is in the stowedposition. In the deployed position (FIG. 13), the rotation of the traytable arm 204 is interfered with by the pin 210. The location of the pin210 is selected so that the tray table arm 204 does not rotate about theseat back pivot pin 212 so far as to contact the seat back 200. In thedeployed position, the load of the tray table 202 and tray table arm 204is supported by the stop mechanism 206, protrusion 208, and/or pin 210.Because the tray table arm 204 is stabilized by the stop mechanism pin210 and does not contact the seat back 200, the seat back 200 may freelymove between its upright and reclined positions without disturbing thetray table 200.

FIGS. 14 and 15 are transparent front views of a seat back 200 with aconcealable tray table 202 in the deployed and stowed positions,respectively. The tray table 202 is pivotally coupled to the tray tablearms 204, which are coupled to the seat back pivot pin (not shown)through z-links 224. In certain embodiments, the tray table arm pivot205 may be integrated into the z-links 224 and allow for rotation of thez-links 224 and tray table arms 204 about the seat back pivot pin. Astop mechanism 206 with a protrusion 208 is fixedly attached to the seatback pivot pin. As the tray table arms 204 move from a stowed positionto a deployed position, the z-link 224 will rotate towards the stopmechanism 206 and protrusion 208. The protrusion 208 will interfere withthe z-link 224 and restrict the motion of the tray table arms 204 beyondthis interference point. The interference point should be chosen suchthat the tray table arms 204 are stopped by the protrusion 208 at thedeployed position without contact between the tray table arms 204 andthe seat back 200. The tray table 202 and seat back 200 will then rotateabout the seat back pivot pin independently, allowing the seat back 200to recline without disturbing the tray table 202 when it is in thedeployed position. When the tray table 202 is in the stowed position,the tray table arms 204 and seat back 200 will share a common axis ofrotation about the seat back pivot pin, and will move together as a unitwhen the seat back 200 moves between reclined and upright positions.

In certain embodiments, the tray table 202 and tray table arms 204 ofFIGS. 6-15 may be adapted for use with a monocoque or semi-monocoqueseat back. The monocoque or semi-monocoque design may provide foradditional space within the seat back 200 to locate the tray table arms204, stop mechanism 206, and any associated hardware. In someembodiments, the stop mechanism 206 may be integrated into the seat backpivot pin or other components of the seat assembly, such as thespreader. The stop mechanism 206 may also be equipped with a set screwor adjustment device to allow for regulation of the clearance betweenthe seat back 200 and tray table arms 204 in the deployed position. Instill other embodiments, the motion of the tray table arms 204 may beregulated by any fixed component, which interferes with the tray tablearms 204 in their deployed position and allows for the tray table arms204 to rotate about the same axis as the seat back 200.

Any of the above described components, parts, or embodiments may take ona range of shapes, sizes, or materials as necessary for a particularapplication of the described invention. The components, parts, ormechanisms of the described invention may be made of any materialsselected for the suitability in use, cost, or ease of manufacturing.Materials including, but not limited to aluminum, stainless steel, fiberreinforced plastics, carbon fiber, composites, polycarbonate,polypropylene, other metallic materials, or other polymers may be usedto form any of the above described components.

Different arrangements of the components depicted in the drawings ordescribed above, as well as components and steps not shown or describedare possible. Similarly, some features and sub-combinations are usefuland may be employed without reference to other features andsub-combinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentswill become apparent to readers of this patent. Accordingly, the presentinvention is not limited to the embodiments described above or depictedin the drawings, and various embodiments and modifications may be madewithout departing from the scope of the claims below.

Suspension Cushion and Cellular Cushion

In certain embodiments of the present invention, as shown in FIGS. 16and 17, a cellular cushion 302 comprises a cellular area 314 and a solidarea 316. The cellular area 314 is made up of a plurality of cells 304that are defined by cell walls 306. The cells 304 of the cellular area314 allow for the cellular cushion 302 to have a combination ofproperties, including anisotropic cushioning and stretch properties. Forinstance, by varying the size and shape of the cells 304 or the cellwall 306 thickness, the cellular cushion 302 may have its propertiestailored to a specific application. The cellular cushion 302 alsocomprises a thickness 308, which may be increased or decreased to varythe amount of cushion, support, or strength of the overall cellularcushion 302.

Still referring to FIGS. 16 and 17, the properties of the cellularcushion 302 may be varied across the area of the cellular cushion, aswell. For instance, one portion of the cellular area 314 of the cellularcushion 302 may have very small cells 304, or thicker cell walls 306 toincrease the relative stiffness of that area of the cellular cushion 302compared to another area with larger cells 304 and/or thinner cell walls306. Similarly, the stiffness of the cellular cushion 302 may varydepending on the direction of force applied to the cellular cushion 302.In certain embodiments, the stiffness or compliance of the cellularcushion 302 to a force applied perpendicular to the thickness 308 may bedifferent than the stiffness or compliance of the cellular cushion 302to a force applied in the plane of the thickness 308 of the cellularcushion 302.

FIGS. 18-20 are front and side views of a cellular cushion 302comprising a cellular area 314 and a solid area 316. The cellular area314 comprises cells 304 defined by cell walls 306. As shown in FIG. 18A,the cells 304 may be configured with different cell sizes and/ordifferent thicknesses of the cell walls 306 at different points of thecellular cushion 302 to provide varying degrees of cushion, stiffness,and/or flexibility. Varying the size of the cells 304, theirarrangement, and the thickness of the cell walls 306 may also be used toalter the amount of cushion, stiffness, and/or flexibility in differentdirections to provide enhanced comfort for a passenger.

Still referring to FIGS. 18-20, the cellular cushion 302 may comprise alumbar support 312 configured to provide additional cushioning andsupport for a passenger. The lumbar support 312, which may be a passivepad or an inflatable bladder, is located within the cellular area 314 ofthe cellular cushion 302. The cellular area 314 may have specific sizingof the cells 304 and cell walls 306 to provide for passive alignment ofthe lumbar support 312 so that it may self-position to fit personsfalling within the fifth to ninety-fifth statistical percentile for bodysize or shape. In certain embodiments, the cellular area 314 around thelumbar support 312 may be configured to only slightly resist vertical orhorizontal movement of the lumbar support 312 as a passenger sits on thecellular cushion 302. However, while the cellular area 314 allowsvertical and horizontal translation of the lumbar support 312, it mayprovide a higher level of support or resistance in a directionperpendicular to the lumbar support 312. In some embodiments, the shapeof the cells 304 may also be changed to provide different cushioningproperties. Hexagonal, circular, and/or square shaped cells 304 may beused. In certain embodiments, other shapes, both regular and irregular,may be used to change or optimize the properties of the cellular cushion302.

The cellular cushion 302 may be formed as a flat or planar sheet, or itmay be molded, formed, or otherwise manufactured with curved orirregular shapes. FIG. 20 shows a side view of a cellular cushion 302with a spinal curve 310 adapted for use in a passenger seat back. Thespinal curve 310 may be a complex curve along both the length and widthof the cellular cushion 302, and may be configured to attempt to fit thelargest number of body shapes, sizes, and/or types. In some embodiments,the shape of the spinal curve 310 may be configured to fit persons whofall within the fifth to ninety-fifth statistical percentile for bodysize or shape. Similarly, the cellular area 314 may be shaped orotherwise configured to provide cushioning adapted to a wide variety ofbody types. In certain embodiments, the cellular 314 area may bepatterned to cushion particular pressure points or to fit a majority ofpassengers. In some embodiments, the cellular area 314, as with thespinal curve 310, may be determined by a statistical analysis of bodytypes, and then configured to fit people that fall within the fifth toninety-fifth statistical percentile for body size or shape. As used inanthropometrics and throughout this disclosure, the fifth toninety-fifth statistical percentile for body size or shape refers to arange on a Gaussian curve, which may be plotted as a bell-shaped curveon a graph. This curve may vary depending on the particular data setconsulted or used, such as with a commercial anthropometric database.For example, the statistical range may vary depending on whether it isapplicable to males or females. In some cases, the statistical range mayinclude all body sizes or shapes that fall within the range of a fifthpercentile female to a ninety-fifth percentile male.

Referring to FIGS. 16-20, a cellular cushion may offer a number ofimprovements or advantages over alternative supporting methods. Thecellular cushion 302 allows for airflow through the cells 304 and aroundthe back of the passenger to reduce heat and the buildup of moisturearound the passenger. The cellular cushion 302 may also provide for alighter, more compact seating arrangement. In certain embodiments, thecellular cushion 302 may be suspended within a seat back such that onlythe perimeter of the cellular cushion 302 is attached. The balance ofthe cellular cushion 302 is then free to deflect as it supports the loadof a passenger, replacing springs. A suspended cellular cushion 302 alsoprovides a dual cushioning method. A passenger may be supported andcushioned both by the deflection of the cellular cushion 302 and by thecompression of the cellular cushion itself.

The cellular cushion 302 may be formed, molded, or otherwise made fromany number of materials including, but not limited to, elastomers,polymers, and/or natural materials. The selection of a suitable materialwill depend upon the geometry of the cellular cushion, including thegeometry, size, and distribution of the cells 304 and cell walls 306,the intended design loads, desired manufacturing processes, and anyapplicable regulatory requirements. The cellular cushion 302 ispreferably made from a material that resists permanent deformation evenunder large displacements and repeated use. In certain embodiments,silicone may be an ideal material for the construction of the cellularcushion 302.

Ergonomic Head Rest

In certain embodiments of the present invention, as shown in FIGS. 21and 22, an ergonomic headrest 320 comprises side supports 322 and a necksupport curvature 324 and an occipital pocket 326. The ergonomicheadrest 320 is moveably affixed to the seat back 330. The headrest sidesupports 322 are configured to provide lateral support to a passenger,both during normal movement and while a passenger may be sleeping.Additionally, the side supports 322 may provide an enhanced feeling ofprivacy, and serve as mounting points for passenger entertainment, suchas integrated speakers. The headrest is designed with a compound curvecomprised of a neck support curvature 324 to support a passenger's neck,and an occipital pocket 326 to support the rear and base of thepassenger's head. The neck support curvature 324 and occipital pocket326 should be shaped based on statistical data to accommodate passengersranging from the fifth to ninety-fifth statistical percentile for bodysize or shape. In order to provide enhanced support, particularly as thepassenger seat moves between reclined and upright positions, in certainembodiments the ergonomic headrest 320 may rotate about a horizontalaxis to articulate into a position that best supports the passenger'shead and neck, as shown by rotation 328.

FIGS. 23A-24 provide side views of an ergonomic headrest 320 attached toa seat back 330 as it translates in a vertical direction to accommodatepassengers that fall within the fifth to ninety-fifth statisticalpercentile for body size or shape. The relative amount of verticaltranslation of the ergonomic headrest 320 from a low position (FIG.23A), through an intermediate position (FIG. 23B) and into an upperposition (FIG. 23C) should take into account the height, torso size,neck size, and general posture of passengers within the fifth toninety-fifth statistical percentile for body size or shape. In certainembodiments, the ergonomic headrest 320 may translate vertically througha linear motion. However, in some embodiments, the ergonomic headrest320 may translate vertically through an arcing motion 329 to betteraccommodate passengers of varying size.

Referring to FIGS. 21-24, the ergonomic headrest 320 may be providedwith additional padding, including foam, cushions, springs, or otherdevices to enhance passenger comfort. In certain embodiments, theergonomic headrest 320 may include aesthetic additions, such as logos,coloring, or stylized fabrics as desired or required.

Any of the above described components, parts, or embodiments may take ona range of shapes, sizes, or materials as necessary for a particularapplication of the described invention. The components, parts, ormechanisms of the described invention may be made of any materialsselected for the suitability in use, cost, or ease of manufacturing.Materials including, but not limited to aluminum, stainless steel, fiberreinforced plastics, carbon fiber, composites, polycarbonate,polypropylene, other metallic materials, or other polymers may be usedto form any of the above described components.

Different arrangements of the components depicted in the drawings ordescribed above, as well as components and steps not shown or describedare possible. Similarly, some features and sub-combinations are usefuland may be employed without reference to other features andsub-combinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentswill become apparent to readers of this patent. Accordingly, the presentinvention is not limited to the embodiments described above or depictedin the drawings, and various embodiments and modifications may be madewithout departing from the scope of the claims below.

Low Rise Spreader and Rocking Seat Recline Motion

In certain embodiments of the present invention, as shown in FIGS. 25and 26, a low-rise spreader 340 comprises a forward motion track 342, anaft motion track 344, a forward seat tube aperture 346, an aft seat tubeaperture 348, and a seatbelt attachment point 349. The motion tracks342, 344 may be configured to accept rollers or other sliding members345 from the passenger seat 300. In certain embodiments, the motiontracks 342, 344 will be disposed on the inside surface of the low-risespreader 340 to eliminate or reduce potential pinch points.

The low-rise spreader 340 provides the attachment and structuralconnection between a passenger seat 300 and the seat tubes (not shown)or other structure of the vehicle or mode of transport. Traditionalspreaders are characterized as generally L-shaped, wherein the structureof the spreader extends above the seat pan to provide structure for thearmrests of the passenger seat 300. The traditional spreader designprovides additional structure to hold the seat back, armrests, andseatbelt attachment. A low-rise spreader 340, typically, though notalways, for use with a passenger seat 300 in which the armrests aremounted directly to the seat back, does not provide additional structureabove the seat pan of the passenger seat 300. The resulting low-risespreader 340 is smaller, lighter, a single piece design with integratedseat tube apertures 346, 348, and motion tracks 342, 344, and a seatbeltattachment point 349, which may be moved forward relative to atraditional spreader for an increase in passenger space. As the low-risespreader 340 does not provide structure above the seat pan of apassenger seat 300, the low-rise spreader 340 may be particularly wellsuited to use with passenger seats 300 that feature monocoque orsemi-monocoque seat backs and seat backs, which are fixed relative tothe seat pan.

Still referring to FIGS. 25 and 26, the low-rise spreader 340 mayinclude a forward motion track 342 and an aft motion track 344. Themotion tracks 342, 344 are configured to displace the passenger seat 300in a rocking motion wherein the passenger seat 300 is displaced downwardand forward for recline. In certain embodiments, the forward motiontrack 342 and aft motion track 344 will be sloped in the same direction(i.e. downward from aft to forward, see FIG. 25). In some embodiments,the forward motion track 342 and aft motion track 344 will be sloped inopposite directions (FIG. 26). While unpowered recline of the passengerseat 300 may be preferable in certain applications, in some embodimentsthe rocking motion of the passenger seat may be assisted or accomplishedthrough the use of springs, gas springs, or electric motors.

FIGS. 27A-27C are schematic illustrations of a passenger seat 300 in anupright position (FIG. 27A), reclined position (FIG. 27B), and acomparison overlay of the upright and reclined positions (FIG. 27C). Therocking motion of the passenger seat 300 due to the motion tracks 342,344 of the low-rise spreader 340 (not shown) may be seen in FIG. 27C.The rocking motion of the passenger seat 300 provides for reclineequivalent to or greater than traditional recline mechanisms with lessintrusion into the space of the aft passenger.

Any of the above described components, parts, or embodiments may take ona range of shapes, sizes, or materials as necessary for a particularapplication of the described invention. The components, parts, ormechanisms of the described invention may be made of any materialsselected for the suitability in use, cost, or ease of manufacturing.Materials including, but not limited to aluminum, stainless steel, fiberreinforced plastics, carbon fiber, composites, polycarbonate,polypropylene, other metallic materials, or other polymers may be usedto form any of the above described components.

Different arrangements of the components depicted in the drawings ordescribed above, as well as components and steps not shown or describedare possible. Similarly, some features and sub-combinations are usefuland may be employed without reference to other features andsub-combinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentswill become apparent to readers of this patent. Accordingly, the presentinvention is not limited to the embodiments described above or depictedin the drawings, and various embodiments and modifications may be madewithout departing from the scope of the claims below.

Seat Pan with Bullnose

In some embodiments of the present invention, as shown in FIGS. 28 and29, a seat pan 360 may comprise a support plate 362, a flexible core364, a top plate 366, and a bullnose 370. The cushion core 364 may besandwiched between the support plate 362 and the top plate 366, whichhas an aperture 368 and located by one or more cushion locators 378. Thebullnose 370 is affixed to the forward edge of the seat pan 360, and isa flexible member comprised of a polymer, rubber, silicone, springmetal, or other material, which may deflect and repeatedly return to itsoriginal position. The bullnose 370 may move between a static position372 and a flexed position 373 along a motion path 374. In certainembodiments, the seat pan may include one or more rollers 376, which maybe configured to interact with a spreader or other seat structure andfacilitate articulation or motion of the seat pan 360 from an uprightposition to a reclined position.

Still referring to FIGS. 28 and 29, the aperture 368 of the top plate366 may be shaped and/or sized to allow forces from the tuberosity ofthe ischium (“ischial tuberosity”) of a passenger to be passed throughthe aperture 368 such that the forces are absorbed and supported by theflexible core 364. The shape and size of the aperture 368 should beselected so that passengers, which range from the fifth to theninety-fifth statistical percentile for body size or shape, will havetheir ischial tuberosity supported by the flexible core 364. Theflexible core 364, which may be a cellular material as described above,may have anisotropic properties or may have differing levels ofstiffness, cushion, or flex across different parts of the aperture 368to provide relief from pressure points or other sources of passengerdiscomfort. In certain embodiments, the flexible core 364 may lock thepassenger's ischial tuberosity in place to provide improved posture andcomfort, even during long periods of sitting.

In some embodiments, the bullnose 370 of the seat pan 360 may beconfigured to provide varying support to the thighs of a passenger,particularly when the passenger reclines the seat. The bullnose 370,which may be formed from any elastomer, polymer, or other material thatprovides adequate flexibility and resilience to avoid permanentdeformation, may flex between a static position 372 and a flexedposition 373 to provide support and comfort to the passenger as thepassenger moves, adjusts his or her seat, or changes position. Incertain embodiments, the bullnose 370 may be adapted to flex so that apassenger's feet remain planted on the ground even when the seat pan 360is reclined and the forward portion of the seat pan 360 may be angledaway from the passenger compartment floor. The bullnose 370, similar tothe seat pan 360, may be upholstered with additional fabric, cushioning,or other supports to provide a more aesthetically pleasing look andfeel, and to improve passenger comfort.

Any of the above described components, parts, or embodiments may take ona range of shapes, sizes, or materials as necessary for a particularapplication of the described invention. The components, parts, ormechanisms of the described invention may be made of any materialsselected for the suitability in use, cost, or ease of manufacturing.Materials including, but not limited to aluminum, stainless steel, fiberreinforced plastics, carbon fiber, composites, polycarbonate,polypropylene, other metallic materials, or other polymers may be usedto form any of the above described components.

Different arrangements of the components depicted in the drawings ordescribed above, as well as components and steps not shown or describedare possible. Similarly, some features and sub-combinations are usefuland may be employed without reference to other features andsub-combinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentswill become apparent to readers of this patent. Accordingly, the presentinvention is not limited to the embodiments described above or depictedin the drawings, and various embodiments and modifications may be madewithout departing from the scope of the claims below

Ergonomic Seat Back

In certain embodiments of the present invention, as shown in FIGS. 30and 31, an ergonomic seat back 380 may comprise a compound spinal curve382, an upper forward panel aperture 384, and a lower forward panelaperture 385. The compound spinal curve 382 may be include a spinalshaped S-curve of varying radius extending along the length of theergonomic seat back 380, and may also include a transverse concavecurvature across the ergonomic seat back 380 to provide lateral supportto a passenger. The spinal curve 382, and more generally the contours ofthe ergonomic seat back 380, should be shaped based on statistical datato accommodate passengers ranging from the fifth to ninety-fifthstatistical percentile for body size or shape.

Still referring to FIGS. 30 and 31, the ergonomic seat back 380 may alsoinclude an upper forward panel aperture 384 and a lower forward panelaperture 385. Similar to the spinal curve 382, the upper and lowerforward panel apertures 384, 385 should be sized and shaped based onstatistical data so that the upper and lower forward panel apertures384, 385 will transfer forces and pressure from passengers fallingwithin the fifth to ninety-fifth statistical percentile for body size orshape to the suspension cushion 394.

FIG. 32 is an assembly drawing of an embodiment of an ergonomic seatback 380. The ergonomic seat back 380 may comprise a forward panel 392and a aft panel 398. A suspension cushion 394 and suspension cushionretaining member 396 may be disposed between the forward panel 392 andthe aft panel 398. When assembled, the forward panel 392 and aft panel398 enclose a volume within which the suspension cushion 394 andsuspension cushion retaining member 396 may be housed. In certainembodiments, the forward panel 392, aft panel 398, suspension cushion394, and suspension cushion retaining member 396 may be shaped toinclude the spinal curve 382 of the ergonomic seat back 380. However, insome embodiments, the suspension cushion 394 may be molded flat and willtake up the spinal curve 382 upon installation into the ergonomic seatback 380.

When the suspension cushion 394 is installed into the ergonomic seatback 380, the suspension cushion is mechanically fixed or bonded aroundits perimeter between the suspension cushion retaining member 396 andthe forward panel 392. The suspension cushion 394 may then extend ordeflect into the space between the suspension cushion and the aft panel398. The deflection of the suspension cushion 394 provides two differenttypes of cushioning. The compression of the suspension cushion 394 iscomplemented by its deflection into the open space enclosed by theforward panel 392 and the aft panel 398. The suspension cushion 394 mayalso provide additional means for adjusting the cushioning provided to apassenger at different areas of the ergonomic seat back 380 through useof a cellular material with anisotropic or variable properties asdescribed above. The extra space contained within the ergonomic seatback 380, particularly in combination with a cellular suspension cushion394, may also enhance passenger comfort by improving air circulationaround the passenger, reducing the buildup of heat and moisture.

The forward panel 392 may comprise upper forward panel aperture 384 andlower forward panel aperture 385. These apertures 384, 385, which may beshaped and sized based on statistical data to accommodate passengersfalling within the fifth to ninety-fifth statistical percentile for bodysize or shape, allow a transfer of forces from the passenger through theforward panel 392 and to the suspension cushion 394. Similarly, thesuspension cushion 394 may comprise upper suspension cushion area 386and lower suspension cushion area 387 that are shaped and sized tocomplement the upper and lower forward panel apertures 384, 385 of theforward panel 392. The suspension cushion retaining member 396 may alsocomprise an upper suspension cushion retaining member aperture 388 and alower suspension cushion retaining member aperture 389. When assembled,the apertures 384, 385, 388, and 389 will align so that the upper andlower suspension cushion areas 386, 387 will be free to absorb forcesfrom a passenger and expand through the suspension cushion retainingmember 396 to provide both deflective and compressive cushioning. Theaft panel 398 may not comprise any apertures, so as to eliminate theneed for an additional aft seat cover, saving space, weight, andcomplexity. However, the aft panel 398 may comprise a stiffeningdepression or rib 399 to provide additional structural support to theergonomic seat back 380. Still referring to FIG. 32, the suspensioncushion retaining member 396 functions to locate and secure thesuspension cushion 394 within the ergonomic seat back 380. The cushionretaining member may be affixed to the suspension cushion 394 andforward panel 392 with mechanical fasteners such as screws, bolts,rivets, or the like, or it may be bonded with adhesives, epoxy, glue, oranother bonding agent. In certain embodiments, the suspension cushion394 may be sonically or friction welded to the suspension cushion 394and/or forward panel 392. The resulting ergonomic seat back 380 may belighter, more compact, simpler to produce, and eliminate the need forsprings or other support mechanisms. After assembly, the ergonomic seatback 380 may be upholstered with fabric and cushions as desired orrequired for additional comfort and aesthetic appearances.

Any of the above described components, parts, or embodiments may take ona range of shapes, sizes, or materials as necessary for a particularapplication of the described invention. The components, parts, ormechanisms of the described invention may be made of any materialsselected for the suitability in use, cost, or ease of manufacturing.Materials including, but not limited to aluminum, stainless steel, fiberreinforced plastics, carbon fiber, composites, polycarbonate,polypropylene, other metallic materials, or other polymers may be usedto form any of the above described components.

Different arrangements of the components depicted in the drawings ordescribed above, as well as components and steps not shown or describedare possible. Similarly, some features and sub-combinations are usefuland may be employed without reference to other features andsub-combinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentswill become apparent to readers of this patent. Accordingly, the presentinvention is not limited to the embodiments described above or depictedin the drawings, and various embodiments and modifications may be madewithout departing from the scope of the claims below.

Any of the above described structures, devices, or components may becombined with one another to provide a complete ergonomic seat design.For example, a monocoque or semi-monocoque seat back may be formed orotherwise manufactured with an ergonomic design incorporating a compoundcurves to fit persons who fall within the fifth to ninety-fifthstatistical percentile for body size or shape. The monocoque orsemi-monocoque seat back may also incorporate apertures and a cellularsuspension cushion with self-adjusting lumbar support designed toalleviate pressure points or areas of discomfort. An ergonomic headrestmay also be incorporated or added to the monocoque or semi-monocoqueseat back. The above described seat back can be combined with a seat panwith bullnose incorporating a flexible core containing cellularmaterial. The seat pan with bullnose may engage with a low-rise spreaderthat is configured to allow for a recline motion that displaces thepassenger seat forward and down. This and any other combinations of theabove described components may be used to provide customized seating asnecessary for any particular application.

That which is claimed is:
 1. An aircraft seat comprising: a seat pan; atleast one spreader coupled to the seat pan, wherein the at least onespreader comprises: a forward track positioned at a forward portionsurface of the spreader; an aft track positioned at a rearward portionsurface of the spreader; and at least one aperture for coupling thespreader to the seat pan; and wherein the at least one spreader iscoupled to the seat pan via the at least one aperture such that thespreader does not extend above a plane formed by the seat pan.
 2. Theaircraft seat of claim 1, wherein the forward track and rearward trackare angled in the same direction.
 3. The aircraft seat of claim 1,wherein the forward track and the rearward track are angled in differentdirections.
 4. The aircraft seat of claim 1, wherein the at least onespreader does not provide additional structure above the seat pan. 5.The aircraft seat of claim 1, further comprising a forward slidingmember that slides within the forward track and a rearward slidingmember that slides within the aft track.
 6. The aircraft seat of claim5, wherein when the forward sliding member slides within the forwardtrack and the rearward sliding member slides within the aft track, theseat is moved between an upright position and a reclined position. 7.The aircraft seat of claim 6, wherein in the reclined position, the seatis displaced downward and forward with respect to the upright position.8. A low rise spreader for a passenger seat comprising: a first trackpositioned at a forward portion of the spreader; a second trackpositioned at a rearward portion of the spreader; and at least oneaperture for coupling the spreader to a seat pan; wherein the spreaderis a unitary piece such that the first track, the second track, and theat least one aperture are integrally formed within the spreader; andwherein movement of the passenger seat within the first track and thesecond track cause a rocking motion of the passenger seat.
 9. The lowrise spreader of claim 8, wherein the spreader is coupled to a seat panof the passenger seat via the at least one aperture.
 10. The low risespreader of claim 8, wherein the passenger seat further comprises afirst sliding member and a second sliding member, wherein the firstsliding member slides within the first track and the second slidingmember slides within the second track to provide the rocking motion. 11.The low rise spreader of claim 10, wherein during the rocking motion,the passenger seat is displaced downward and forward into a reclinedposition.
 12. The low rise spreader of claim 8, wherein the first trackand the second track are angled in the same direction.
 13. The low risespreader of claim 8, wherein the first track and the second track areangled in different directions.
 14. An aircraft seat comprising: a seatpan; a single piece spreader coupled to the seat pan and having anintegrally formed first track and an integrally formed second track; afirst sliding member; and a second sliding member; wherein the firstsliding member slides within the first track and the second slidingmember slides within the second track; and wherein movement of the firstsliding member and the second sliding member within the first track andthe second track causes the seat to move between an upright position anda reclined position.
 15. The aircraft seat of claim 14, wherein thesingle piece spreader further comprises at least one aperture, whereinthe single piece spreader is coupled to the seat pan via the at leastaperture.
 16. The aircraft seat of claim 14, wherein the single piecespreader is only coupled to the seat pan such that the single piecespreader does not provide additional structure above the seat pan. 17.The aircraft seat of claim 14, wherein in the reclined position, theseat displaced downward and forward with respect to the uprightposition.
 18. The aircraft seat of claim 14 wherein the first track andthe second track are disposed on an inside surface of the single piecespreader.
 19. The aircraft seat of claim 14, wherein the first track ispositioned at a forward portion of the single piece spreader, and thesecond track is positioned at a rearward portion of the single piecespreader.
 20. The aircraft seat of claim 14, wherein the single piecespreader further comprises a seat belt attachment point.